Sachs 501/3BF, Repair Manual

Page 1: ...paraturanleitung Nr 3028 8 2 D E F Repair Manual Manuel de Reparations SACHS 501 4A KF 501 4AKFX 501 3BKF 501 4BKF 501 3BF 501 4 BF Ausgabe August 1978 Edition AugusVAout 1978 FICHTEL SACHS AG 0 8720...

Page 2: ...ing the exhaust system cylinder and cylinder head Replacing the small end bush Assembling the engine Adjusting the seleetor Ignition timing Operations after engine overhaul Fitting and lubricating the...

Page 3: ...nits have bcen Included in this Repair Manual Unit Previously N Aom Perlormance Hp kW Kilowatt TIghlening kpm Nm Newtonmeter torque Engine speed APM Imin per minute PREFACE le prosent manual de rE par...

Page 4: ...t Papierfiller am Ansaug rohr im Fahrgeslell aufgesteckt SACHS 501 3 BKF 501 4 BKF w ith grey cast cylinder with large cooling fins Carburettor clamped al cylinder socket intake silencer with paper fi...

Page 5: ...B emslieht 6 VOlt 5Well Ilop hght 6 Volt 5Wall Feu op 6 Ils 5 watts Ziind eilpunkl L 2nvn Cl9 22 voro T Spa k OOvJnce 1 2mmI19 _ 22 belme TDC Avanee aI allumaoo L 2mm 19 22 avant le PMH Unte Il he _...

Page 6: ...chnnging Ignilion 80SCH magneto genoralor marn right 6 Volt 15 Watt leil light SVait 2Wan lop ligl l 6 Vol 5Watl 0 5 2 s O O mm 0 Sl I CalbulOlIIO BING single lide ca burenor WIII slide valve 12 mm B...

Page 7: ...Allumage Magn o g n atnce BOSCH HauPlhch 6 Volt 15 Weu maln I gIl 6 Volt 15 Wal Pha e 6 voll 1S wau Schlulllich 6 Voll 2 Wan 13 I hgll 6 Volt 2Wa Feu AR 6 volt 2 wattS B m lich 6 Volt 5Wau Slap I 9h...

Page 8: ...6 18 17 2B Anderungs Nr I Amendment No Modificatif No 19 20 r 31 i 1 j 35 a REPARATUR WERKZEUGE UND MONTAGE VORRICHTUNGEN REPAIR TOOlS AND MOUNTING JIGS OUTIllAGE DE REPARATION ET BlOCS DE MONTAGE Aus...

Page 9: ...aining strip E tractor lor magneto flywhe el M 26 x 1 5 Extractor loollor tayshalt bustring Exlractor and draw in too or smatt end bushing Extraclor 1001 for oil sealing rings Extractor hook 3 mm piec...

Page 10: ...en SACHS Montage Vorrichtung aulgenommen Siehe Reparatur Werkzeuge und Montage Vorrichtun gen Seile 7 und 8 SQwie SMD Milleilung Nr 2 78 Mounl the englne lo the repair 119 As iIIuslraled in Figs 2 and...

Page 11: ...rs Remove slone asbestos joint Crankcase cover magn eto side Unscrew crankcase cover magneto side b Remova gaskei Pav attention 10 dowel sleeves Dr ive sproc ket Set lever d onto relaining pin e and l...

Page 12: ...sation d un nouveau bloc de montage enga ger la cle ti griffe comme montre sur la 119ure Pull off the sprocket Arraeher le pignon de chaine Make sure that the number of teath and the chain Faire atten...

Page 13: ...druH key d and take off Ihe centrifugal washer from the crank pin Cylinder head and cylinder Unscrew cylinder head and cylinder Remove cylinder flange gasket Note The cylinder can be rebored four lime...

Page 14: ...u On model steel connecting rod lake the needle baaring oul of the small end boss Crankcase cover on clutch side and layshaft gear Unscrew cra n case cover remove gaskeI Pay etten tion to tiow Ieeves...

Page 15: ...ter head screws M 6 28 Turn in the screw c until it touches tha foreing pin than lighten it for another 1 5 2 turns and remove circlip dl Slacken back the screw Remove the forcing pin steel disc and h...

Page 16: ...change lever m Unscrew 2 hexagon socket head screws n with spring rings lift up gear change lever m and pull off selector ass v from the starter axle Remove shims from the starter axle Dismantle gear...

Page 17: ...wendung der neuen Montage Vorrichlung 2 Slift Il the new repair jig is used screw in 2 studs 1 M 8 x 80 schrauben 1 M 8 x 80 werden nicht von Fa Fichtel are not supplied by Fichtel Sachs and apply the...

Page 18: ...OVB compleIe pedal shaft dcvice 2 with shim 1 and washer 4 mm Ihick Iying undernealh it Remove layshaft c Fig 26 and 27 Take 011 5uccessively shims sclector gears and spacer rings Irom Ihe main shaft...

Page 19: ...ff the stop screw b Releasc the kickstarter spring remova the crank of the kickstilrtcr and take the kickstarter mechanism out of the crankCilSC Pay atlantion 10 the washer 1 mm thick Unscrew stop scr...

Page 20: ...e ane limb and insert both hooks at an angle Apply initial tension evenly to both limbs and take care that shalt and lorcing screw are allgned Attention Il the seal stieks fast oxydized the metal rim...

Page 21: ...assembly of c rankcase half on magneto sid e Belore installation lill the grooves ol the oi l seals with high melling point grease Alvaniil 3 and lubricate the seilling lips slightly Press the bearing...

Page 22: ...ngs Note On crankcase half with collar fill the 3 bores on the main shaft bearing for the oil seallFig 33 with grease Layshaft bearing Remove defective bronze bush d Fig 34 with e ractor repair 1001 N...

Page 23: ...easured over balh webs wilh washeer 3 Fig 38 0 8 mm Ihick Existing axial play Permissible axial play Difference to be compensated 13 80 mm 28 05 mm 41 85 mm 41 30 mm 0 55 mm 0 05 mm O_50 mm By means o...

Page 24: ...he crankcase half up to approx 100 C M ain shaft bea ring Press in the grDoved ball bearings t up to the stop Layshaft bearing Press in the grooved ball bearings 2 up to the stop Insart circlip a FIQ...

Page 25: ...he sealing ring Carburettor The carburettor type and the jet sizes are selected by means of tests in the factory Fine adjustments jf required are to be made by varying the jet needte position Raising...

Page 26: ...ing screw B3 Nut C Throttle slide C2 Throttle slide spring FNeedle jet G Jet needle G2 Holding plate H Jet Hz Plug screw HJ Sealing ring M Choke M 7 Shouldered screw M s Nipple 5 Wet air filter U Cove...

Page 27: ...ew 83 Nut 85 Gasket C ThlOttle slide C2 Throttle slide spring C3 Adjusting serew C Spring FNeedle jet G Jet needle G2 Holding plate G Washer H Jet H2 Plug screw Hl Sealing ring M3 Choke slide M Thrust...

Page 28: ...ning the armature The adjustment can also be made thraugh the inspection hoies in the magneto Ilywheel Rep laeing the contact breaker 1 Remove set ol contact breakers Unscrew bearing pin il screwed in...

Page 29: ...tappe hole points towards the thread ol the main shaft selector rod Screw the selector rod and selector key tightly together Insert cups and pressure springs into the main shaft and secure them with...

Page 30: ...of the pawl 0 1 mm Put the pawl spring 5 on the adjusting plale with its offset end pointing to the eft and move Ihe offset end from left to right over the straight end of Iho spring Make sure that bo...

Page 31: ...cup 1 with MoIy kote pasle Hook lension spring 4 lo the lever of the cam cup and lo the grooved pin 5 insert cam cup with locking plate adjusling screw 2 Fig 91 and Iocking screw I Fig 91 Place fork...

Page 32: ...ing inwards into the bearing cup Entrainement du compteur Demontage Devisser la vis raccord a Retirer I axe avec engrenage dl la buselure bl et la rondelte c en veillant fl Ja rondelle e Enlever le jo...

Page 33: ...sely alleet fuel consumption engine perlormanee and noise but are also against regulations and possibly entail penalties Cylinder head Unscrew cylinder head and remove carbon deposits in the combusIio...

Page 34: ...uts Clamp the connecting rod with the eccentric bolts d Insolt wilhdrawal bolt c wilh guidc sleeve f and thrust bush g into the small end bush Mount adapter sleeve h tighten nut i and press out the sm...

Page 35: ...djustability in 0 02 mm increments Insert reamer and with the aid ol adjusting nuts b and c adjust it to the diameter ol the boro ol the small end bush Remove the reamer from Ihe small end bush loosen...

Page 36: ...f the two selector gears is eorrect Spadng ring Seleetor gear 3rd gear symmetrical Spadng ring Seleelar gear 4th gear with its recess pointing downwards Insert layshaft Three speed gear The same seque...

Page 37: ...e bearing inner race 41 3 mm OiSlance 1 3 mm Existing axial play 0 1 mm Permissible axial play 1 2 mm Oilference to be compensaled 40 0 mm 41 3 mm 42 6 mm 41 3 mm 1 3 mm 0 1 mm 1 2 mm Durch Ausgleichs...

Page 38: ...he auf Starterradauflage Distance from mating surface to 4 1 mm starter gear support Kickstarterachse Ma wie im Bild gezeigt mit Starterrad 2 Scheibe 1 mm dick unter dem Starterrad 42 4 mm Kickstarter...

Page 39: ...spring with its offset end xl as illustratcd Slide the ratchet on the kickstarter spring and Jnsert at the same time the spring end into the bore see aHow at the chamler behind the raising curve of t...

Page 40: ...mm Exampla Magneto side crankcase half Distance from mating surface with 38 3 mm gaskei lo collar for starter shaft Clutch side crankcase half Distance from mating surface to 4 1 mm slarter gear supp...

Page 41: ...ln shaft Pullogelher magneto side crankcase half and clutch side crankcase half on engines with kickstarter pay atlention 10 shimming washers underneath the starter gear Fasten both crankcase halves w...

Page 42: ...rubber grommet c paying attention to the stamped in markings I New stator plates have no markings and mus be positioned in their longitudinal slots Coat 3 cross head screws bl M4x 14 and washers with...

Page 43: ...J play However it must not be strained Ult the selector assembly inlroduce the pin see arrow of the lever 3 into the selector boss 4 and push the seIec ter assembly down Position the adjuSling plate v...

Page 44: ...e from the thread of the plvot screw 2 and from Ihe housing Position the adjusling plale in ils slols and tighten with 2 haxagon sockathead screws 3 M 6 x 20 and spring rings Degrease the thread Tri o...

Page 45: ...ble would be a zero play Adjust unequal play by positioning the adjusting plate 3 If there Is too great a play e g at the seleetor tooth 10 wards the 3rd gear loosen hexagon socket head screws positio...

Page 46: ...emove retaining plate Tightening lorque 80 90 Nm 8 9 kpm Insert 9 clutch spri ngs with some grease into the clutch case Mount the spring plate in such a manner that its protrusions engage with thc spr...

Page 47: ...ng 1 5 2 turns and rotate layshaft gear until the discs have centered with the clutch hub of the layshaft gear Remove large forcing tool forcing pin and layshaft gear Fit 1 mm thick washer b Fit laysh...

Page 48: ...ungsseite auf Lagerung fUr side crankcase cover to bearing for Schaltwelle 7 9 mm selector shaft 7 9 mm M 6 5 mm Distance 6 5 mm vorhandenes Axialspiel 1 4 mm Existing axial play 1 4 mm zulassiges Axi...

Page 49: ...at the graphite coated side poinls towards the crankcase On model steel connecting rod insert the oiled needle bearing into the small end boss Heat the piston to 70 BlY C and fit it lo the connecting...

Page 50: ...nter and the liring point must be measured anew and marked with the spark advance timing gauge Example 1 Place piston at top dead center using the spark advance timing gauge 2 Apply Ihe chisel mark to...

Page 51: ...and tighten with 2 nulS M 5 reclprocal y On SACHS 501 3 SKF 501 4 SKF 501 3 SF and 501 4 SF fil the carburettor and lighten damping ring Magneto side crankcase cover Insert 2 dowel sleeves into the cr...

Page 52: ...r lvel Ensure lh rl the chain is correctly lensioned sl rck of ch rin 1 2 cm Control cables Install the contral throttle cable and choke on SACHS 501 4 AKF and 501 4 AKF X Note The nipple M 8 Fig 42 f...

Page 53: ...el tent th lt l the clutch lever still touches the crankcase cover b the clutch lever lifts off its rest point in the crankcase cover when pulling the clutch lever li the handle bar after apprOl 1 mm...

Page 54: ...will be carried out through the adjustment screw anrl the contra I wire on the starting lever Unscrew the throtlle slide stop screw 2 or 5 and adjusl Ihe control cable in such a manner that the throtl...

Page 55: ...ight circuit b green with red spiral Stop light 6 Volt 5 Watt Short circuiting wire e black Ignition cable d C Magneto generator C Stop light armature Cl Generating armature Ca Ignition armature C7 Se...

Page 56: ...ide and oulside the engino aro nal covercd by our warranty lUBRICATION ANO MAINTENANCE CHART J o lubricant quanlilv of lubrieanl and mainlenance o oper tiona N Intake ileneer and wet ir filte Pon h oU...

Page 57: ...oil in Ihe engina can run oul lock bores and pou u approx 300 cc of SACHS gear I F 5 part No 0263015OO5 or SAE 80 as de bcd under oillcvcl check Control cabin It spec al lubllcating nIpples a e fmed t...

Page 58: ...I Igntlion sel I Check and IIdjusi Ihe bruke pol l alte 500 km aher 1000 km I and then ahar 3000 km l_ f_f j Apply BOSCH orease Fl l v 4 to Ihe Il brie ting pad for Ihe breake r i cam I Engino and e...

Page 59: ...isse il rou lements tres ch luds Graisse BOSCH Ft 1 v 4 Ft 1 v 8 APPENDIX Ventilation of the magneto housing In order to give you the possibilily to adjust the ven tilalion ol the magneto housing also...